ガスアトマイズ金属粉

概要 ガスアトマイズ金属粉

Gas atomized metal powder refers to metallic particulate materials produced by atomizing molten alloy feedstock with high velocity inert gas jets. This imparts a spherical morphology ideal for additive manufacturing, metal injection molding, and other applications.

Gas atomization features:

• Excellent control over particle shape, size distribution
• Applicable to reactive alloys including titanium, aluminum
• Provides high purity starting material for advanced processes
• Powders tailored for hot isostatic pressing, heat treatment
• Supports precise repeatable powder characteristics

Continue reading to learn about composition options, particle qualities, usage applications, and specifications for gas atomized powders.

Alloy Types of gas atomized metal powder

Various alloys are gas atomizeable into fine spherical powders:

Alloy Category	材料	作曲
ステンレス鋼	304, 316, 17-4PH, 303, 410	Fe/Cr/Ni + trace elements
工具鋼	H13、M2、M4	Fe + V, Mo, W carbides
コバルト合金	CoCr, CoCrW, CoCrMo	Co/Cr + tungsten/molybdenum
ニッケル合金	Inconel 625 & 718	Ni/Cr/Fe/Mo
チタン合金	Ti-6Al-4V, Ti-6242	Ti/Al/V/Sn/Zr/Mo

表1： Overview of alloy systems commercially available in gas atomized powder

Specialty additive manufacturing and industry-specific alloys for aerospace/biomedical use may have minimum order quantities or lead times.

粉体の特徴

Typical particle characteristics achieved via inert gas atomization:

特徴	詳細	意義
粒子形状	球形度が高い	粉体の流動性と充填密度を向上
サイズ範囲	10 μm～150 μm	Controlled distribution optimized for end use
構成	Alloying maintained within ± 0.5 wt%	Preserves mechanical properties
純度	Up to 99.9% achievable	Reduces contaminants and inclusions
表面酸化物	<50 nm thick passivation layer	Maintains excellent powder recyclability

表2： Overview of particle qualities in gas atomized metal powders

Precise properties repeatably produced to meet certification needs across aerospace, medical, automotive and industrial categories.

製造工程

• Typical steps in inert gas atomization:

1. Induction or arc melting forms alloy melt under protective cover gas
2. High purity inert gas (Ar or N2) forced through specialized nozzles
3. Molten stream breaks into fine droplets rapidly cooling into powders
4. Powders settle into collection hoppers below
5. Classified via sieves to normalize distribution
6. Packaged and shipped to clients in protective atmosphere

• Critical process parameters:
  • Nozzle design – governs particle size distribution
  • Gas pressure – affects particle velocity and cooling rate
  • Melt pouring rate – influences size distribution shape
• Environment (vacuum vs. controlled atmosphere) depends on reactivity

の応用 ガスアトマイズ金属粉

申し込み	メリット	例
積層造形	High density parts from excellent powder flow and packing	航空宇宙部品、医療用インプラント
金属射出成形	Good moldability for small intricate shapes	Turbine blades, nozzle components
溶射コーティング	Dense coatings from deformable particle impacts	Wear-resistant surfaces
Braze pastes	Join complex geometries	Heat exchangers, electrical contacts
熱間静水圧プレス	Minimize closure issues with spherical particles	Consolidate cast turbine blades
Heat treatment precursors	Tailorable grain structure	Precipitation hardening alloys

表3： Overview of applications leveraging qualities of gas atomized metal powders

The consistency and purity offered by gas atomization suits most advanced metal powder processes where repeatability is critical.

仕様 ガスアトマイズ金属粉

Gas atomized powders are validated against various standard specifications:

スタンダード	説明
ASTM B214	Validation using optical microscopy for uniformity and lack of satellites
AMS 7008	Aerospace material specification including inert gas atomization method
ASTM F3049	Standard guide for characterizing properties of metal powders for AM
ASTM F3056	積層造形用ニッケル合金粉末の仕様
ISO 21818	Specification for DMLS/SLM production grade stainless steels

表4： Industry standards commonly applied to inert gas atomized powders

Reputable producers will provide full certification paperwork and testing results for each powder lot to validate compliance.

サプライヤーと価格

サプライヤー	材料	参考価格
サンドビック・オスプレイ	Ti alloys, Ni alloys, tool steels	$100+/kg
カーペンター添加剤	Stainless steels, cobalt alloys, Cu	$50〜$150/kg
プラクセア	Ti alloys, Al alloys, silicon powders	$100+/kg
LPWテクノロジー	Tool steels, stainless steels, Inconels	$50〜$500/kg
SLMソリューション	カスタム合金の開発	$250+ per kg

表5： Selection of companies supplying gas atomized metal powders with approximate pricing

Most suppliers offer standard alloys with 2-4 week lead times in small quantities. Custom formulations and unique particle optimization is also possible working directly with gas atomization vendors.

Pros and Cons vs Alternatives

パラメータ	ガス噴霧	水の霧化	プラズマ霧化
粒子形態	球形度が高い	More irregular spheroids	ほとんどが球形
粒度分布	Tight distribution, tailorable	より広い分布	タイトな分配
Alloys compatible	Most commercial alloys	限定合金	Wide range including reactive metals
kgあたりのコスト	Moderate $50-150 per kg	Lower $20-100 per kg	Higher $150-500 per kg
Productivity rates	Up to 10,000 kg per day capacity	Very high >50,000 kg per day	<1,000 kg per day

表6： Comparison of gas atomization against alternative powder production methods

Gas atomization strikes an optimal balance between capabilities and economics while delivering powder volumes suited for commercial production.

制限事項

• Minimum batch sizes dictate use of 100kg+ material to justify machine setup
• Limited ability to economically atomize high melting point alloys like tungsten
• Powders not as spherical as plasma atomization and contain some satellites
• Oxide thickness slightly higher than vacuum plasma alternatives
• Steep initial capital costs around $1-5 million for turnkey system
• Requires improved powder handling/storage compared to virgin materials

よくあるご質問

Q: What is the benefit of gas atomized powder over virgin materials for part production?

A: Gas atomized powders offer superior consistency and repeatability. Engineering the powder morphology and grain structure from the start enables mature processes producing certified components meeting the highest industry requirements in aerospace and medical sectors.

Q: What precautions are necessary when handling gas atomized powders?

A: As fine metallic materials prone to oxidation, inert storage and handling protocols are recommended. These include moisture-controlled argon filled glove boxes and workers wearing personal protective equipment to minimize explosion, inhalation or contamination risks. Never allow contact with water or organic compounds. Special facility construction is not necessarily required though local regulations may apply.

Q: What level of repeatability can be expected lot-to-lot with gas atomized powders?

A: Reputable producers guarantee powder distributions within ±10% between batches. Minor variations still warrant re-optimization as standard practice even from the same powder supplier if acceptable component tolerances are tight. Certificates of analysis document consistency.

Q: How long can unused gas atomized powders remain viable in storage?

A: Best practice stores powder in protective argon in sealed containers avoiding temperature extremes. If kept below 30°C and 50% relative humidity with minimal oxygen and moisture, powders lasts many months before needing refresh cycles in the glove box to maintain flow and reuse properties.

Q: What technical support do powder vendors provide for part qualification and certification?

A: Reputable vendors have material scientists and validation personnel to give application guidance and interface with part buyers through the testing process to certificate powders. They want demonstrated repeatability meeting regulated standards to expand use of materials in more demanding applications. Expect detailed paperwork and protocols from any established supplier.

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